3-48 2002 Buell S3T: Engine
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5. Remove pilot from right crankcase roller race. Thor-
oughly clean gearcase cover, removing all metal chips/
shavings. Blow out all oil passages using compressed
air.
ASSEMBLY/INSTALLATION
1. See Figure 3-68. Install oil pump drive gear (5) and pin-
ion gear on pinion shaft.
a. Slide oil pump gear drive gear (5) over pinion
shaft (1). Drive gear must align with shaft key (4).
b. Align keyway (3) in ID of pinion gear with shaft
key (4).
c. Slide pinion gear over shaft key (4) and against oil
pump drive gear (5).
2. See Figure 3-59. Install nut (11).
a. Clean threads on pinion shaft and nut.
b. See Figure 3-69. Install CRANKSHAFT LOCKING
TOOL (Part No. HD-43984) to gearcase with “Side
A” facing out, over pinion shaft, with two screws.
c. Apply several drops of LOCTITE THREADLOCKER
262 (red) to threads of nut.
d. Install nut to pinion shaft. Tighten nut to 35-45 ft-lbs
(48-61 Nm).
3. Liberally apply engine oil to bushings, shafts, and gears.
Install all cam gears into bushings of right crankcase
half, properly aligning timing marks of cam gears and
pinion gear. See Figure 3-62.
NOTE
Because of the larger diameter additional gear (which
meshes with the pinion gear) on the outboard end of the rear
intake (15-2) cam gear, the rear exhaust (15-1) and front
intake (15-3) cam gears must both be installed before the
rear intake (15-2) cam gear is installed.
CAUTION
Use only the correct gearcase cover gasket (see parts
catalog for Part No.). Using pre-2000 model year gasket
will obstruct oil galley and result in engine damage.
4. See Figure 3-59. Install a new seal (6) and new dry
gearcover gasket (9) on gearcase cover (17).
Figure 3-67. Line Reaming Pinion Shaft Bushing
Figure 3-68. Aligning Pinion Gear
3545a
1. Pilot (Part No. HD-94812-87)
2. Reamer (Part No. HD-94812-1)
21
b0342x3x
1
2
3
4
5
1. Pinion Shaft
2. Timing Mark on Pinion Gear
3. Keyway
4. Shaft Key
5. Oil Pump Drive Gear
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